Positioning an object with respect to a target location

ABSTRACT

Systems and methods are provided for positioning an object with respect to a target location, such as for auto-focusing. One implementation includes a positioning device, which includes a reference object having a plurality of dark-shaded bars arranged in parallel with and separated from each other by spaces equal to a width of each of the bars. The positioning device also includes a motor configured to move in a reciprocating manner and a sensor configured to sense at least one of the bars or spaces. The motor is connected to the reference object or the sensor and moves the reference object or sensor with respect to the other. The motor is configured to stop at a target location in two phases of motion.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. patent application Ser. No. 14/851,645 for Positioning an Object with Respect to a Target Location filed Sep. 11, 2015 (and published Mar. 16, 2017 as U.S. Patent Publication No. 2017/0076125), now U.S. Pat. No. 9,652,648. Each of the foregoing patent application, patent publication, and patent is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to systems and methods for positioning an object with respect to a target location and more particularly relates to motor control systems and methods for quickly and accurately positioning an object.

BACKGROUND

In various environments where optical devices are used to focus on an image or object, achieving a quality image hinges on the accuracy of the focusing process. To simplify the use of some optical equipment, the technology of automatic focusing can be used. Auto-focusing is used in a variety of applications, such as in digital cameras and video cameras. Auto-focus is also used in barcode scanners, precision drafting devices, mechanical actuators, and other devices. In particular, a barcode scanner may comprise an optical grid used in the focusing process.

As used herein, the term “optical grid” may represent a linear or two-dimensional arrangement of optical elements uniformly arranged with a predetermined spacing between them. The optical grid may include light sources for emitting beams of light and light sensors for detecting the light that is reflected off of an image or transmitted through an image. The light sources and light sensors may be paired in a one-to-one ratio. The sensors can be used for distinguishing between dark-shaded or opaque portions and light-shaded or transparent portions of the optical grid.

The auto-focusing device may also include components, such as a range-finder, for calculating the distance to an object. Range-finders can utilize acoustic reflective methods, stereoscopic optical methods, time-of-flight optical methods, patterned light, and other methods known in the art. In one example, a single laser can use the principle of parallax to determine distance. From the calculated distance, a lens can be moved to a target location for auto-focusing. A need exists for controlling quickly and accurately the movement of a device (e.g., a lens) for the purpose of auto-focusing or for other similar purposes related to positioning an object at or near a target location. In this regard, any improvements in the ability to position quickly and accurately an object can be beneficial in auto-focusing technologies used for cameras, barcode scanner, and other devices that may utilize auto-focusing. The process of positioning any object at any target location quickly and accurately is desired in other fields as well.

SUMMARY

Accordingly, the present invention embraces systems and methods for positioning an object at or near a target location. One method described in the present disclosure includes a first step of providing an optical grid having a first set of optical elements and a second set of optical elements, whereby the first set of optical elements is optically distinguishable from the second set of optical elements. The method further includes continuously moving first and second optical sensors in a forward direction and at a constant speed with respect to the first and second sets of optical elements. The first and second optical sensors are offset from each other by a predetermined distance, wherein transitions are encountered when one of the optical sensors senses one of the first set of optical elements and the other of the optical sensors senses one of the second set of optical elements. Also, the method includes sensing when one of the optical sensors reaches a target location and beginning a clock cycle counter when the target location is reached. The method also includes encountering a first transition beyond the target location. The clock cycle counter is stopped when the first transition beyond the target is encountered to obtain a first clock cycle count. The method also includes continuously moving the first and second optical sensors in the forward direction at the constant speed until at least a second optical transition beyond the target is encountered and then stopping the movement of the first and second optical sensors in the forward direction. The method further includes the step of reversing the direction of movement of the first and second optical sensors and continuously moving the first and second optical sensors in a reverse direction and at the constant speed. Then, the first transition beyond the target location is encountered again and a step is executed for beginning the clock cycle counter when the first transition beyond the target is encountered in the reverse direction. The method includes stopping the movement of the first and second optical sensors when the clock cycle counter reaches the first clock cycle count.

In another exemplary embodiment, a positioning device is described in the present disclosure. The positioning device comprises a reference object including a plurality of dark-shaded bars arranged in parallel and separated from each other by spaces equal to a width of each of the bars. The positioning device further includes a motor configured to move in a reciprocating manner with respect to the bars. Also, the positioning device includes first and second sensors connected to the motor, where each of the first and second sensors is configured to sense one of the bars or spaces. The motor is configured to stop at a target location in two phases of motion.

The present disclosure also defines a non-transitory computer-readable medium configured to store a processing sequence executable by a processing device. The processing sequence comprises a sensor motion unit for controlling the movement of at least one sensor in a first direction at a constant velocity with respect to a pattern of optically alternating shades. The processing sequence also includes a transition detecting unit for detecting when the at least one sensor encounters transitions between the optically alternating shades. Furthermore, the processing sequence includes a target detecting unit for detecting a first time when the at least one sensor encounters a target location. Also, the processing sequence comprises a clock cycle counting unit for counting a number of clock cycles from a time when the target detecting unit first encounters the target location to a time when the transition detecting unit encounters a first transition beyond the target location.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts a barcode scanning system according to an embodiment of the present invention.

FIG. 2 schematically depicts electrical and mechanical components of a positioning device incorporated in the barcode scanner shown in FIG. 1 according to an embodiment of the present invention.

FIG. 3A schematically depicts a reference object of an optical grid according to an embodiment of the present invention.

FIG. 3B schematically depicts the reciprocating device shown in FIG. 2 according to a first embodiment of the present invention.

FIG. 3C schematically depicts the reciprocating device shown in FIG. 2 according to another embodiment of the present invention.

FIG. 4 schematically depicts the positioning module shown in FIG. 2 according to an embodiment of the present invention.

FIG. 5 graphically depicts the velocity of the motor shown in FIG. 3 according to an embodiment of the present invention.

FIG. 6 graphically depicts the operation of the reciprocating device shown in FIG. 2 in spatial relationship with the reference object shown in FIG. 3A according to an embodiment of the present invention.

FIG. 7 schematically depicts a flow diagram showing the operation of the positioning module shown in FIG. 2 according to an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention is directed to systems and methods for positioning an object with respect to a target location. For example, the present invention may be incorporated in or may include barcode scanners or other devices (e.g., auto-focus cameras) that utilize a motor for positioning a lens at an optimum location for greatest focus.

FIG. 1 illustrates an embodiment of a barcode scanning system 10 including a barcode scanner 12 and a barcode 14. It should be understood that the barcode scanner 12 may be used to scan other barcodes and the barcode 14 can be scanned by other barcode scanners. The barcode 14, as is known, includes a number of parallel lines 16 or bars having various widths. The lines 16 of the barcode 14 are separated from each other by spaces 18 also having various widths. The barcode scanner 12 includes a housing 20 that contains barcode scanning components therein.

FIG. 2 is a block diagram showing an embodiment of a positioning device 24, which may be housed within the housing 20 of the barcode scanner 12. According to other embodiments, the positioning device 24 may be used in other devices that perform an auto-focusing feature or that perform a position feature for positioning a lens or other object at a target location.

The positioning device 24 includes both electrical and mechanical components. The electrical components of the positioning device 24 include a processor 26, a clock 28, a memory device 30, and a motor controller 32. The mechanical component of the positioning device 24 includes a reciprocating device 34, which moves in forward and reverse directions and is controlled by electrical signals from the motor controller 32.

In some embodiments, the memory device 30 may store a positioning module 36, which is configured to include logic that is utilized by the processor 26 as instructions so as to enable the processor 26 to position the reciprocating device 34 with respect to a target location. According to various embodiments of the present invention, the positioning module 36 may be configured as software, hardware, firmware, and/or any suitable combination of these. Software of the positioning module 36 may be stored in the memory device 30, while hardware may be configured in the processor 26 or other micro-processing devices of the positioning device 24.

FIG. 3A illustrates an embodiment of a reference object 37 having a number of parallel dark-shaded or opaque bars 38, each having the same width. The reference object 37 also includes light-shaded or transparent bars 40 or spaces, which separate the dark-shaded bars 38. Each of the light-shaded bars 40 includes the same width, which is also the same width as that of the dark-shaded bars 38.

FIG. 3B illustrates a first embodiment of the reciprocating device 34 shown in FIG. 2. The reciprocating device 34 is used in conjunction with the reference object 37 of FIG. 3A. The reciprocating device 34, according to embodiments associated with FIG. 3B, includes a motor 42, a light source 44, and a light sensor 46. Other embodiments may include one or more light sources 44 and at least the same number of light sensors 46. The motor 42 (e.g., a piezo motor) may be directly connected to a lens 48 or other object that is to be positioned at a desired location. Therefore, the lens 48, motor 42, light source 44, and light sensor 46 are connected together and move in unison in a reciprocating manner within the housing 20 of the barcode scanner 12. The movement of the reciprocating device may be transverse to the parallel bars 38, 40 of the reference object 37 shown in FIG. 3A.

FIG. 3C illustrates a second embodiment of the reciprocating device 34 shown in FIG. 2. According to this embodiment, the reciprocating device 34 includes the reference object 37 of FIG. 3A. The reciprocating device 34, according to embodiments associated with FIG. 3C, includes the motor 42 and the reference object 37. The motor 42 moves the reference object 37 with respect to the light source 44 and the light sensor 46 connected at a fixed location inside the housing 20 of the barcode scanner 12. As mentioned above, other embodiments may include one or more light sources 44 and at least the same number of light sensors 46. The motor 42 may be directly connected to the lens 48 or other object that is to be positioned at a desired location. Therefore, the lens 48, motor 42, and reference object 37 are connected together and move in unison in a reciprocating manner within the housing 20 of the barcode scanner 12. The reciprocating device 34 may be moved in this embodiment such that the direction of movement is perpendicular to the parallel bars 38, 40 of the reference object 37.

In operation, a target location of the lens (or other object) is detected or known with respect to the reference object 37. The location may be calculated based on range-finding components in the barcode scanner 12. The range-finding components determine a distance to a subject (e.g., the barcode 14) and correlate this distance to a target location on the reference object 37. For instance, the target location may be determined for providing the best location for focusing other light sensing elements for sensing reflections of light beams from a laser source of the barcode scanner 12 off of the subject (e.g., the barcode 14).

FIG. 4 illustrates an embodiment of the positioning module 36 shown in FIG. 2. In this embodiment, the positioning module 36 includes a signal processing unit 50, a motion control unit 52, a transition detecting unit 54, a target detecting unit 56, and a clock cycle counter unit 58. The signal processing unit 50 receives signals from the sensor 46 or sensors and interprets these signals. The motion control unit 52 controls the movements of the motor 42, which thereby moves the sensor 46 with respect to the reference object 37 (FIG. 3B) or moves the reference object 37 with respect to the sensor 46 (FIG. 3C). Particularly, the motion control unit 52 controls the stopping and starting of the motor and the direction of travel of the motor (e.g., forward or reverse).

The transition detecting unit 54, in some implementations, may be part of the signal processing unit 50 and is used for detecting when the position of the motor is at a transition or border between one of the dark-shaded bars 38 and one of the light-shaded bars 40.

The target detecting unit 56 may receive input from a separate sensor for determining the range or distance to a subject. Thus, when the subject is in focus using a range-finding device, the target detecting unit 56 notes that corresponding location with regard to the relative location of the light sensor 46 with respect to the reference object 37. The details of the process of detecting the target location are described below with respect to FIG. 6.

The clock cycle counter unit 58 operates in conjunction with the signal processing unit 50 based on signals detected by the transition detecting unit 54 and target detecting unit 56. For example, a process for positioning the lens 48 at an optimum location for greatest focus may include a two-phase process according to the teachings of the present invention.

The two-phase process includes a first phase that involves the motion control unit 52 moving the motor 42 (and either the sensor 46 as in FIG. 3B or the reference object 37 as in FIG. 3C) in a first (forward) direction at a constant velocity. The transition detecting unit 54 may be used at this point to determine when a constant velocity is reached, such as by timing from one transition to the next until the times are the same. When the target detecting unit 56 detects the target location, the clock cycle counter unit 58, which has been reset to zero, begins counting the number of clock cycles until the next transition beyond the target location is detected by the transition detecting unit 54.

In the meantime, the motion control unit 52 is moving the motor 42 along in the forward direction at the constant speed and continues to move the motor 42 well beyond the first transition encountered after the target location. After at least one additional transition is detected by the transition detecting unit 54, the motion control unit 52 is configured to stop the motion in the first (forward) direction, which is the end of the first phase.

The second phase begins when the motion control unit 52 reverses the motion of the motor 42 so that it travels in a second (reverse) direction. The reason for travelling well beyond the first transition in the first phase is that when the motion control unit 52 reverses the direction, it takes a short amount of time at the beginning of the second phase for the motor 42 to reach a constant speed.

By the time that the first transition beyond the target is encountered again (this time in the reverse direction), the velocity of the motor is constant. The transition detecting unit 54 detects that first transition again and the clock cycle counter unit 58, which again has been reset to zero, begins counting clock cycles a second time. When the clock cycle count reaches the same count that was detected when the motor 42 was travelling in the forward direction, the clock cycle counter unit 58 signals the motion control unit 52 to stop the motor 42. Thus, the motor 42 can be stopped accurately and quickly at the target location.

FIG. 5 shows a graph 60 depicting an exemplary operation of the motor 42 shown in FIGS. 3B and 3C according to one implementation. The graph 60 shows the velocity of the motor 42 over time when the motor 40 is travelling in either a forward direction or reverse direction. The stages of velocity of the motor 40 can be defined by a first rest stage 62, an acceleration stage 64, a constant velocity stage 66, a deceleration stage 68, and a second rest stage 70.

The time period for the first and second rest stages 62, 70 may include any length of time and may even be zero if the operation of the motor 40 immediately follows or is immediately followed by an operation of the motor 40 in the opposite direction. Also, the constant velocity stage 66 may include an indefinite length of time and may even be zero if the deceleration stage 68 closely follows the acceleration stage 64.

FIG. 6 is a graph 80 showing signals obtained by the light sensor 46. The graph 80 illustrates a small section of the dark-shaded or opaque bars 38 and light-shaded or transparent bars 40 of the reference object 37. The graph 80 also shows a target location 82. The target location 82 corresponds to the place where the motor 42 is to be positioned. One goal of the present invention includes positioning the motor 42 as close to the target location 82 as quickly and accurately as possible.

In operation, the light source 44 illuminates the reference object 37. The light sensor 46 and reference object 37 are moved with respect to each other by the motor 42 in a reciprocating fashion. In particular, the light sensor 46 or reference object 37 is moved while the other remains fixed, whereby the relative direction of movement is substantially perpendicular with respect to the bars 38, 40. At a constant velocity, the light sensor 46 obtains signal A.

Light sensor 46 is configured to detect the light reflected from the bars 38, 40. Therefore, a dark-shaded bar 38 provides little or no reflection, designated by a low value (e.g., zero) in signal A and a light-shaded bar 40 provides great or maximum reflection, designed by a high value (e.g., one) in signal A.

Since the width of the dark-shaded bars 38 and light-shaded bars 40 are configured with equal widths in some embodiments, and since the bars 38, 40 are scanned at a constant velocity, signal A will have a square-wave shape, as shown. It should be noted that signal A is illustrated with respect to time, but is also matched up with the physical features of the reference object 37 in the physical realm to show the results obtain with respect to the bars 38, 40 when scanned at a constant velocity.

Transitions 84, 86, 88, 90, 92, 94, and 96 are encountered when the light sensor 46 detects a change from a dark-shaded bar 38 to a light-shaded bar 40 or from a light-shaded bar 40 to a dark-shaded bar 38. As used herein, the term “transition” refers to the border between the dark-shaded bars 38 and light-shaded bars 40. The transitions 84, 86, 88, 90, 92, 94, and 96 can be utilized by the processor 26 as a reference for locating the target 82 with respect to the bars 38, 40.

Also shown in the graph 80 of FIG. 6 is a first phase (Phase 1), which shows the relative movement between the light sensor 46 and the bars 38, 40 at a constant velocity in a first direction. Point i shows the point when the target detecting unit 56 detects the target 82. At this point, the scanning continues at the constant velocity in the first direction and the clock cycle counter unit 58 is started. The clock cycle counter unit 58 is configured to count the number of clock cycles of the clock 28 from the starting point i when it is first started until point ii when the first transition 90 beyond the target 82 is reached. At this point (i.e., point ii), the clock cycle counter unit 58 is stopped and the number of clock cycles that were counted is stored in the memory device 30 to be used at a later time, as will be explained below.

Phase 1, showing the scanning in the first direction, continues at the constant velocity beyond the target 82, beyond the first encountered transition 90, and beyond at least one additional transition (e.g., 92, 94, 96). The reason for travelling beyond the target 82 to such an extent is that when the motor 40 decelerates (i.e., during the deceleration stage 68) to a momentary stop and then immediately reverses direction, the motor 40 must go through the acceleration stage 64 in the reverse direction to reach the constant velocity stage 66 before the first transition 90 beyond the target 82 is encountered again.

Phase 2, showing the scanning in the opposite direction from the first direction, includes accelerating to the constant velocity stage 66. The at least one additional transition 92, 94, 96 is encountered during Phase 2 and then the first transition 90 beyond the target 82 is encountered while travelling at a constant velocity. At point iii, the first transition 90 is encountered and the clock cycle counter unit 58, which has been reset, is started again. The clock count is compared with the original clock count to determine when the same number of clock counts is encountered in the reverse direction. When the clock counts are the same at point iv, the motor 42 stops at the target location 82.

FIG. 7 is a flow diagram showing an embodiment of a method 98 of operation of the positioning module 36 shown in FIGS. 2 and 4. The method 98 includes a first block 100, which indicates that a step is executed to control the movement in a first direction of a sensor (e.g., sensor 46) with respect to a reference object (e.g., reference object 37). According to the embodiments of FIGS. 3B and 3C, either the sensor or reference object can be moved with respect to the other. Block 102 indicates that a step is executed to detect when the sensor encounters transitions in the reference object (e.g., transitions from white-to-black, black-to-white, light-to-dark, dark-to-light, transparent-to-opaque, opaque-to-transparent, etc.).

In block 104, the method 98 includes detecting when the target location is encountered. For instance, the step depicted by block 104 may include a range-finding method, such as a single laser using parallax. Block 106 indicates the step of counting the number of clock cycles from the time the target location is encountered to the time when the first transition beyond the target location is encountered. After at least one additional transition is encountered, the direction of the sensors is reversed, as indicated in block 108. Reversing the direction of the sensors marks the end of Phase I and the start of Phase II, as mentioned above.

The method 98 of FIG. 7 further includes block 110, which indicates that a step is executed such that when the first transition beyond the target location is encountered in the reverse direction, a new count begins to count to the same clock cycle count as before. When the same clock cycle count is reached, according to block 112, the sensor is stopped.

At this stopped location, the positioning process is complete and the object to be moved has been quickly and accurately positioned at the desired place. With respect to the barcode scanner 12, the process can be used to position the location of a lens for focusing on the barcode 14 at a target location defined as the optimum place to achieve the greatest focus.

It should be understood that the routines, steps, processes, or operations described herein may represent any module or code sequence that can be implemented in software or firmware. In this regard, these modules and code sequences can include commands or instructions for executing the specific logical routines, steps, processes, or operations within physical components. It should further be understood that two or more of the routines, steps, processes, and/or operations described herein may be executed substantially simultaneously or in a different order than explicitly described, as would be understood by one of ordinary skill in the art.

* * *

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

The invention claimed is:
 1. A method for positioning an object, the method comprising the steps of: providing an optical grid having a first set of optical elements and a second set of optical elements, the first set of optical elements being optically distinguishable from the second set of optical elements; moving an optical sensor in a forward direction with respect to the optical grid, wherein transitions are encountered when the optical sensor senses a border between one of the first set of optical elements and one of the second set of optical elements; beginning a clock cycle counter when a target location is reached; stopping the clock cycle counter when a first transition beyond the target location is encountered to obtain a first clock cycle count; continuously moving the optical sensor in the forward direction until at least a second transition beyond the target location is encountered; reversing the direction of movement of the optical sensor and moving the optical sensor in a reverse direction; resetting and beginning the clock cycle counter a second time when the first transition beyond the target location is encountered in the reverse direction; and stopping the movement of the optical sensor when the clock cycle counter reaches the first clock cycle count.
 2. The method of claim 1, wherein the optical sensor is coupled in a fixed relationship to the object, whereby the object is positioned with respect to the target location.
 3. The method of claim 1, wherein the first set of optical elements includes a plurality of parallel dark-shaded or opaque bars and the second set of optical elements includes a plurality of parallel light-shaded or transparent bars, the dark-shaded or opaque bars being parallel with and interspersed with the light-shaded or transparent bars.
 4. The method of claim 3, wherein the width of each of the bars of the first and second sets of optical elements is the same.
 5. The method of claim 1, comprising utilizing a piezo motor to move the optical sensor in the forward and reverse directions.
 6. The method of claim 1, wherein the target location is positioned between two adjacent transitions.
 7. The method of claim 1, wherein at least the second transition beyond the target location includes a plurality of transitions.
 8. A method comprising: moving, to a target location, either a reference object including a plurality of shaded or opaque bars arranged in parallel with and separated from each other by spaces or a sensor configured to sense at least one of the bars and spaces of the reference object, wherein the moving to the target location consists essentially of: moving in a forward direction, with a motor, either the reference object or the sensor; stopping the movement in the forward direction; moving in a reverse direction, with the motor, either the reference object or the sensor; and stopping the movement in the reverse direction, comprising stopping, with the motor, either the reference object or the sensor at the target location.
 9. The method of claim 8, wherein: the method comprises sensing the target location while moving in the forward direction, and counting clock cycles until a first transition beyond the target location is encountered; and the stopping the movement in the forward direction comprises stopping after at least a second transition beyond the target location is reached.
 10. The method of claim 9, wherein: the counting the clock cycles until the first transition beyond the target location is encountered provides a first count; and the method comprises: beginning counting, during the moving in the reverse direction, clock cycles when the first transition beyond the target location is reached to provide a second count, and stopping the movement of the motor when the second count is the same as the first count.
 11. The method of claim 10, wherein each transition is an intersection between a bar and a space.
 12. The method of claim 8, wherein a plurality of sensors are arranged on the motor.
 13. The method of claim 8, wherein an optical lens is connected to the motor.
 14. The method of claim 8, wherein the motor is incorporated in a housing of a barcode scanner.
 15. A method, comprising: moving an optical sensor in a forward direction with respect to an optical grid, wherein the optical grid comprises a first set of optical elements and a second set of optical elements, the first set of optical elements being optically distinguishable from the second set of optical elements, wherein transitions are encountered when the optical sensor senses a border between one of the first set of optical elements and one of the second set of optical elements; beginning a clock cycle counter when a target location is reached; stopping the clock cycle counter when a first transition beyond the target location is encountered to obtain a first clock cycle count; continuously moving the optical sensor in the forward direction until at least a second transition beyond the target location is encountered; reversing the direction of movement of the optical sensor and moving the optical sensor in a reverse direction; resetting and beginning the clock cycle counter a second time when the first transition beyond the target location is encountered in the reverse direction; and stopping the movement of the optical sensor when the clock cycle counter reaches the first clock cycle count.
 16. The method of claim 15, wherein the optical sensor is coupled in a fixed relationship to the object, whereby the object is positioned with respect to the target location.
 17. The method of claim 15, wherein the first set of optical elements includes a plurality of parallel dark-shaded or opaque bars and the second set of optical elements includes a plurality of parallel light-shaded or transparent bars, the dark-shaded or opaque bars being parallel with and interspersed with the light-shaded or transparent bars.
 18. The method of claim 17, wherein the width of each of the bars of the first and second sets of optical elements is the same.
 19. The method of claim 15, comprising utilizing a piezo motor to move the optical sensor in the forward and reverse directions.
 20. The method of claim 15, wherein the target location is positioned between two adjacent transitions. 